TM &P TECHNICAL MANUAL OPERATOR AND FIELD MAINTENANCE MANUAL WITH REPAIR PARTS AND SPECIAL TOOLS LIST FOR

Transcription

1 TM &P TECHNICAL MANUAL OPERATOR AND FIELD MAINTENANCE MANUAL WITH REPAIR PARTS AND SPECIAL TOOLS LIST FOR FILTER/SEPARATOR, LIQUID FUEL, 50-GPM (NSN ) 100-GPM (NSN ) 350-GPM (NSN ) DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENT OF THE ARMY July 2008

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3 TM &P WARNING SUMMARY In normal operation, the filter/separator is filled with diesel/jet fuel. Diesel/jet fuel may explode if subjected to high temperatures, sources of ignition or high pressure. Keep all open flames, cigarettes, and any other sources of fire/flame or ignition a minimum of 50 yards from any fuel servicing operations. Failure to follow this warning may result in injury or death to personnel. Rapid filling of the filter/separator can cause a buildup of static electricity, leading to possible explosion. Fill filter/separator units slowly to minimize static buildup. Failure to follow this warning may result in injury or death to personnel. Diesel/jet fuel is toxic and can severely affect skin, eyes and the respiratory tract. Personnel must wear appropriate hand and eye protection (nitrile gloves and goggles). Wash skin thoroughly with soap and water if exposed. In case of contact with diesel/jet fuel, flush eyes with clear water for at lest 15 minutes. Failure to follow this warning may result in injury or death to personnel. Diesel/jet fuel fumes are toxic in high concentrations. Avoid prolonged breathing of vapors. Operation and maintenance of the filter/separator should be performed only in a well-ventilated environment. Failure to follow this warning may result in injury or death to personnel. Failure to properly ground the filter/separator units can cause a buildup of static electricity, leading to possible explosionl. Always verify that the grounding rod is properly configured to dissipate static electricity. Failure to follow this warning may result in injury or death to personnel. Failure to properly torque the lid bolts on the 350-GPM filter/separator unit can cause fuel leaks, leading to possible explosion. Failure to follow this warning may result in injury or death to personnel. Failure to properly seat the v-band and torque the bolt securing the v-band on the 50-GPM and 100-GPM filter/separator units can cause fuel leaks, leading to possible explosion. Follow maintenance procedures carefully to ensure that v-band is properly seated. Failure to follow this warning may result in injury or death to personnel. a

4 TM &P Improper installation of o-rings and gaskets when repairing the filter/separator units can cause fuel leaks, leading to possible explosion. Follow inspection and maintenance procedures carefully to ensure integrity of o-rings and gaskets. Failure to follow this warning may result in injury or death to personnel. Exceeding the maximum pressure limits for the filter/separator units can cause fuel leaks, leading to possible explosion. Do not exceed a static pressure of 115 psi in the 50-GPM or 100-GPM filter/ separator units. Failure to follow this warning may result in injury or death to personnel. Exceeding the maximum pressure limits for the filter/separator units can cause fuel leaks, leading to possible explosion. Do not exceed a static pressure of 225 psi in the 350-GPM filter/separator unit. Failure to follow this warning may result in injury or death to personnel. Rapid closure of downstream valves or nozzles during fueling with a high-pressure pump can result in overpressurization of vessel and cause fuel leaks, leading to possible explosion. Failure to follow this warning may result in injury or death to personnel. Avoid prolonged breathing of vapors. Only use the filter/separator in a well-ventilated environment. Removing head assembly requires a two-man lift to avoid injury to personnel. b

5 TM &P LIST OF EFFECTIVE PAGES Dates of issue for original pages is: Original July 2008 Total number of pages in this publication is 100 consisting of the following: Page No. *Change No. Title Warnings i-ii WP (2 pages) WP (10 pages)....0 WP (2 pages) WP (2 pages) WP (2 pages) WP (4 pages) WP (2 pages) WP (2 pages) WP (6 pages) WP (4 pages) WP (4 pages) WP (2 pages) WP (2 pages) WP (2 pages) WP (2 pages) WP (2 pages) WP (4 pages) WP (4 pages) WP (10 pages)....0 WP (4 pages) WP (4 pages) WP (2 pages) WP (2 pages) *Zero in this column indicates an original page A/(B blank)

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7 TM &P HEADQUARTERS, DEPARTMENT OF THE ARMY WASHINGTON, D.C. 31 JULY 2008 TECHNICAL MANUAL OPERATION AND FIELD MAINTENANCE WITH REPAIR PARTS AND SPECIAL TOOLS LIST FILTER/SEPARATOR, LIQUID FUELS, 50-GPM (NSN ) 150-GPM (NSN ) 350-GPM (NSN ) CURRENT AS OF 2 JULY 2008 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the Army Electronic Product Support (AEPS) Web site. The Internet address is The DA Form 2028 is located under the Public Applications section on the AEPS public home page. Fill out the form and click on SUBMIT. Using this form on the AEPS site will enable us to respond to your comments quicker and to manage the DA Form 2028 program better. You may also mail, , or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LC-LMPP / TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL The address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN or Commercial (309) DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. i

8 TM &P TABLE OF CONTENTS WP Sequence No. WARNING SUMMARY a LIST OF EFFECTIVE PAGES A TITLE PAGE i HOW TO USE THIS MANUAL iii General Information Description and Data Controls and Indicators Operator Preventive Maintenance Checks and Services Preparation for Operation Operation Field Preventive Maintenance Checks and Services Troubleshooting Element Replacement Sight Gauge Replacement Differential Pressure Gauge Replacement Fuel and Water Drain Valve Replacement Purge Valve Replacement Bayonet Replacement Camlock Replacement References Maintenance Allocation Chart Introduction Maintenance Allocation Chart (MAC) Repair Parts and Special Tools List (RPSTL) Components of End Item and Basic Issue Items Lists Additional Authorization List Expendable and Durable Items List Mandatory Replacement Parts ii

9 TM &Pi HOW TO USE THIS MANUAL OVERVIEW This technical manual describes operation, maintenance and repair requirements for the filter/separator units. The manual has been prepared in work package format. Each work package is intended as a stand-alone unit, providing specific information and instructions for a single topic or task. Each work package lists tools and expendable items required for the procedures contained in that work package. To use the maintenance work packages in this manual properly, you should familiarize yourself with the entire work package before beginning the maintenance task. Information in this manual is divided into 24 work packages and an index. Work packages are numbered sequentially. CONTENTS WP No. Title Description General Information General information about the manual and equipment Description and Data Location and description of major components and equipment specifications Controls and Indicators Description of all operator controls and their functions Operator Preventive Maintenance Checks and PMCS table for equipment operators Services Preparation for Operation Procedures to prepare the units for use Operation Operating procedures for unit Field Preventive Maintenance Checks and Services Field-level PMCS table Troubleshooting Steps for diagnosing and correcting problems with the units Fuel Draining Procedures for draining fuel from units Element Replacement Procedures for replacing defective filter elements Sight Gauge Replacement Procedures for replacing defective sight gauge Differential Pressure Gauge Replacement Procedures for replacing defective differential pressure gauge Fuel and Water Drain Valve Replacement Procedures for replacing defective drain valve Purge Valve Replacement Procedures for replacing defective purge valve Bayonet Replacement Procedures for replacing defective bayonet Camlock Replacement Procedures for replacing defective camlock References List of documents referenced in this manual Maintenance Allocation Chart Introduction Introduction to the MAC chart Maintenance Allocation Chart (MAC) MAC charts for the units Repair Parts and Special Tools List (RPSTL) Illustrated parts list Components of End Item and Basic Issue Items Lists List of items shipped with the units Additional Authorization List Additional equipment authorized to be used with units Expendable and Durable Items List List of consumable materials and items used in maintaining the units Mandatory Replacement Parts List of parts that must be replaced during maintenance procedures iii/(iv blank)

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11 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM GENERAL INFORMATION SCOPE 1. Type of Manual: Operator and Field level maintenance and repair parts manual. 2. Equipment Name: 50-GPM Liquid Fuel Filter/Separator Unit, Frame Mounted, Type II, Class A 100-GPM Liquid Fuel Filter/Separator Unit, Frame Mounted, Type III 350-GPM Liquid Fuel Filter/Separator Unit, Frame Mounted, Type IV 3. Purpose of Equipment: Removal of undissolved water and solid contaminants from petroleum fuels. Figure 1. Filter/Separator Units

12 TM &P MAINTENANCE FORMS AND RECORDS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DAPAM , Functional Users Manual for The Army Maintenance Management System (TAMMS); DA PAM , Functional Users Manual for the Army Maintenance Management System- Aviation (TAMMS-A); or AR , Army Logistics Readiness and Sustainability. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATION (EIR) If your filter/separator needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don t like about your equipment. Let us know why you don t like the design or performance. Put it on an SF 368 (Product Quality Deficiency Report). Mail it to the address specified in DA PAM , or as specified by the contracting activity. We will send you a reply. CORROSION PREVENTION AND CONTROL Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem. If a corrosion problem is identified, it can be reported using SF 368, Product Quality Deficiency Report. Use of key words such as corrosion, rust, deterioration, or cracking will ensure that the information is identified as a CPC problem. The form should be submitted to the address specified in DA PAM DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For procedures to destroy this equipment to prevent its use by the enemy, refer to TM , Procedures for Destruction of Materiel to Prevent Enemy Use. END OF WORK PACKAGE

13 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM DESCRIPTION AND DATA EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES The filter/separator units covered in this manual consist of a metal pressure vessel with a removable cover. Inside the vessel are multiple canisters and filter elements. The vessel is fitted with a differential pressure gauge, sight glass, camlock-style inlet and outlet ports, a manually-operated ball valve, and a air purge valve. The filter/separator includes a separate detector kit that can be connected to the unit for testing purposes. The entire unit is mounted inside a protective metal frame. Grounding rods are attached to the frame to provide dissipation of static charges. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS The following paragraphs contain physical and functional descriptions of the major components of the filter/separator. The location and appearance of the major components are illustrated in the following figures

14 TM &P Figure 1. Major Components of 50-GPM Filter/Separator

15 TM &P Table GPM Filter/Separator Major Components No. Item Description 1 Ground Rod The grounding rod is driven into the ground and connected to the frame using a copper cable. The grounding rod allows for the dissipation of static electricity that would otherwise build up in the unit as fuel flows through the vessel. 2 Head Assembly The head assembly is a removable cover secured to the top of the vessel by a stainless steel retaining band. The head assembly is removed to allow access to the coalescer elements inside the vessel. 3 Retaining Band The retaining band is a stainless steel belt that is used to secure the head assembly to the top of the vessel A bolt mechanism is used to tighten the retaining band in place. 4 Outlet Coupling Filtered fuel exits the vessel through the outlet coupling at the top of the vessel. The outlet coupling is a standard camlock-type connection for fuel hoses. 5 Differential Pressure Gauge The differential pressure gauge displays the pressure difference across the filter/separator elements. When filter elements become contaminated, the flow through the elements is impeded, causing an increase in pressure. The Operator monitors the differential pressure gauge and changes the elements when the pressure difference exceeds a threshold value. 6 Inlet Coupling Fuel to be filtered enters the vessel through the inlet coupling located at the bottom of the vessel. The inlet coupling is a standard camlock-type connection for fuel hoses. 7 Water Drain Valve A lever-operated ball valve used by the Operator to evacuate water from the sump. 8 Canister The canister separates the coalesced water from the fuel. 9 Coalescer The coalescer is the primary filtering component of the filter separator. The coalescer coalesces suspended water and removes particulate matter from the fuel before it exits the Filter/Separator through the outlet. 10 O-ring The o-ring provides a seal between the head assembly and the vessel. 11 Bayonet Mount The bayonet provides a mounting surface for the canisters containing the coalescer elements. 12 Detector Kit The detector kit consists of a short pipe nipple with camlock fittings on either end that allow it to be installed in the outlet flow of the filter/separator unit. The nipple is equipped with a probe that allows for sampling of the fuel exiting the filter/separator for testing purposes. 13 Sight Gauge The sight gauge indicates to the operator the level of water collected in the sump. 14 Fuel Drain Valve A lever-operated ball valve used by the Operator to evacuate fuel from the vessel. 15 Frame and Vessel The vessel and frame are a single, welded assembly. The vessel contains the coalescer elements of the filter/separator assembly. The frame protects the vessel and attached components from damage and provides a stable, level mounting platform for the vessel. 16 Purge Valve The purge valve is located on top of the vessel s cover assembly. The Operator activates the purge valve to allow air trapped inside the vessel to escape with minimal fuel loss

16 TM &P Figure 2. Major Components of 100-GPM Filter/Separator

17 TM &P Table GPM Filter/Separator Major Components No. Item Description 1 Ground Rod The grounding rod is driven into the ground and connected to the frame using a copper cable. The grounding rod allows for the dissipation of static electricity that would otherwise build up in the unit as fuel flows through the vessel. 2 Head Assembly The head assembly is a removable cover secured to the top of the vessel by a stainless steel retaining band. The head assembly is removed to allow access to the coalescer elements inside the vessel. 3 Retaining Band The retaining band is a stainless steel belt that is used to secure the head assembly to the top of the vessel A bolt mechanism is used to tighten the retaining band in place. 4 Differential Pressure Gauge The differential pressure gauge displays the pressure difference across the filter/separator elements. When filter elements become contaminated, the flow through the elements is impeded, causing an increase in pressure. The Operator monitors the differential pressure gauge and changes the elements when the pressure difference exceeds a threshold value. 5 Inlet Coupling Fuel to be filtered enters the vessel through the inlet coupling located at the bottom of the vessel. The inlet coupling is a standard camlock-type connection for fuel hoses. 6 Water Drain Valve A lever-operated ball valve used by the Operator to evacuate water from the sump. 7 Canister The canister separates the coalesced water from the fuel. 8 Coalescer The coalescer is the primary filtering component of the filter separator. The coalescer coalesces suspended water and removes particulate matter from the fuel before it exits the Filter/Separator through the outlet. 9 O-ring The o-ring provides a seal between the head assembly and the vessel. 10 Bayonet Mount The bayonet provides a mounting surface for the canisters containing the coalescer elements. 11 Detector Kit The detector kit consists of a short pipe nipple with camlock fittings on either end that allow it to be installed in the outlet flow of the filter/separator unit. The nipple is equipped with a probe that allows for sampling of the fuel exiting the filter/separator for testing purposes. 12 Sight Gauge The sight gauge indicates to the operator the level of water collected in the sump. 13 Outlet Coupling Filtered fuel exits the vessel through the outlet coupling at the bottom of the vessel. The outlet coupling is a standard camlock-type connection for fuel hoses. 14 Fuel Drain Valve A lever-operated ball valve used by the Operator to evacuate fuel from the vessel. 15 Frame and Vessel The vessel and frame are a single, welded assembly. The vessel contains the coalescer elements of the filter/separator assembly. The frame protects the vessel and attached components from damage and provides a stable, level mounting platform for the vessel. 16 Purge Valve The purge valve is located on top of the vessel s cover assembly. The Operator activates the purge valve to allow air trapped inside the vessel to escape with minimal fuel loss

18 TM &P Figure 3. Major Components of 350-GPM Filter/Separator

19 TM &P Table GPM Filter/Separator Major Components No. Item Description 1 Grounding Rod The grounding rod is driven into the ground and connected to the frame using a copper cable. The grounding rod allows for the dissipation of static electricity that would otherwise build up in the unit as fuel flows through the vessel. 2 Head Assembly The head assembly is a removable cover secured to the top of the vessel by lid bolts. The head assembly is removed to allow access to the coalescer elements inside the vessel. 3 Differential Pressure Gauge The differential pressure gauge displays the pressure difference across the filter/separator elements. When filter elements become contaminated, the flow through the elements is impeded, causing an increase in pressure. The Operator monitors the differential pressure gauge and changes the elements when the pressure difference exceeds a threshold value. 4 Outlet Coupling Filtered fuel exits the vessel through the outlet coupling at the top of the vessel. The outlet coupling is a standard camlock-type connection for fuel hoses. 5 Fuel Drain Valve A lever-operated ball valves that can be opened by the Operator to evacuate fuel from the vessel. 6 Canister The canister separates the coalesced water from the fuel. 7 Coalescer The coalescer is the primary filtering component of the filter separator. The coalescer coalesces suspended water and removes particulate matter from the fuel before it exits the Filter/Separator through the outlet. 8 O-ring The o-ring provides a seal between the head assembly and the vessel. 9 Bayonet Mount The bayonet provides a mounting surface for the canisters containing the coalescer elements. 10 Detector Kit The detector kit consists of a short pipe nipple with camlock fittings on either end that allow it to be installed in the outlet flow of the filter/separator unit. The nipple is equipped with a probe that allows for sampling of the fuel exiting the filter/separator for testing purposes. 11 Sight Gauge The sight gauge indicates to the operator the level of water collected in the sump. 12 Water Drain Valve A lever-operated ball valves that can be opened by the Operator to evacuate water from the sump. 13 Inlet Coupling Fuel to be filtered enters the vessel through the inlet coupling located at the bottom of the vessel. The inlet coupling is a standard camlock-type connection for fuel hoses. 14 Frame and Vessel The vessel and frame are a single, welded assembly. The vessel contains the coalescer elements of the filter/separator assembly. The frame protects the vessel and attached components from damage and provides a stable, level mounting platform for the vessel. 15 Purge Valve The purge valve is located on top of the vessel s cover assembly. The operator activates the purge valve to allow air trapped inside the vessel to escape with minimal fuel loss

20 TM &P EQUIPMENT DATA Height Width Length Weight Item Maximum Flow Rate Table GPM Filter/Separator Data 32.5 inches 17 inches 20 inches 66 lbs 50 GPM Value/Description Maximum Working Pressure 76.7 PSI Operating Temperature Range Minimum: -25 F (-32 C) Maximum: 140 F (60 C). Storage Temperature Range Minimum: -50 F (-46 C) Maximum: 160 F (71 C) Fuels Processed A-A Fuel Oil, Diesel; For Posts, Camps and Stations MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4, JP-5, And JP-5/JP-8 ST MIL-DTL Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP-8), NATO F-35, and JP Height Width Length Weight Item Maximum Flow Rate Table GPM Filter/Separator Data 32 inches 20 inches 24 inches 88 lbs 100 GPM Value/Description Maximum Working Pressure 76.7 PSI Operating Temperature Range Minimum: -25 F (-32 C) Maximum: 140 F (60 C). Storage Temperature Range Minimum: -50 F (-46 C) Maximum: 160 F (71 C) Fuels Processed A-A Fuel Oil, Diesel; For Posts, Camps and Stations MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4, JP-5, And JP-5/JP-8 ST MIL-DTL Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP-8), NATO F-35, and JP

21 TM &P PRINCIPLES OF OPERATION Fuel under pressure enters the Filter/Separator s inlet connection, then passes from the center of the coalescers, and flows out through the coalescer and canister. The coalescer and canister separates suspended water and removes particulate matter from the fuel before it exits the Filter/Separator through the outlet. END OF WORK PACKAGE Item Table GPM Filter/Separator Data Value/Description Height 39.5 inches Width 33 inches Length inches Weight 364 lbs Maximum Flow Rate 350 GPM Maximum Working Pressure 150 PSI Operating Temperature Range Minimum: -25 F (-32 C) Maximum: 140 F (60 C). Storage Temperature Range Minimum: -50 F (-46 C) Maximum: 160 F (71 C) Fuels Processed A-A Fuel Oil, Diesel; For Posts, Camps and Stations MIL-DTL-5624 Turbine Fuel, Aviation, Grades JP-4, JP-5, and JP-5/JP-8 ST MIL-DTL Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP-8), NATO F-35, and JP /( blank)

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23 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM CONTROLS AND INDICATORS CONTROLS AND INDICATORS The operating controls and indicators are illustrated in figure 1, and their names and functions are listed in table 1. The numbers in the ITEM column of the table correspond to the index numbers on the illustration. NOTE The controls and indicators are identical for all filter/separator units. Only the 100-GPM filter/separator unit is shown to illustrate the controls and indicators

24 TM &P Figure 1. Filter/Separator Controls and Indicators

25 TM &P END OF WORK PACKAGE Table 1. Filter/Separator Controls and Indicators Item Name Description 1 Purge Valve Manually operated valve that allows air trapped inside the filter/separator to be released. 2 Differential Pressure Gauge Indicates the difference in pressure between the inlet and outlet of the filter/separator in pounds per square inch differential (PSID). This is used as an indication of the condition of the filter elements. Clean elements should generate between 2 and 4 PSID. The maximum allowable pressure differential is 15 PSID. 3 Sight Gauge Indicates the water level in the filter sump. 4 Water Drain Valve Ball valve that is used to drain water from the filter sump. 5 Fuel Drain Valve Ball valve that is used to drain fuel from the vessel /( blank)

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27 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES INTRODUCTION A PMCS table, Table 1, has been provided so you can keep your equipment in good operating condition and ready for its primary mission. Always observe WARNINGS and CAUTIONS appearing in the PMCS table. WARNINGS and CAUTIONS appear before the procedure to which they apply. WARNINGS and CAUTIONS must be observed to avoid serious injury to yourself and others and to prevent damage to the equipment. The following paragraphs describe the columns of the PMCS table: 1. Item No. Numbers in this column are for reference. When completing DA Form 2404 (Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indicating a fault. Item numbers appear in the order of completion for the intervals listed. 2. Interval. This column tells you when the corresponding procedure must be performed. BEFORE procedures must be done before you operate or use the equipment for its intended mission. DURING procedures must be done during the time you are operating or using the equipment for its intended mission. AFTER procedures must be done immediately after you have operated or used the equipment. 3. Item to Check/Service. This column lists the name of the item to be checked or serviced. 4. Procedure. This column gives the procedure to follow to perform the required check or service and determine if the equipment is ready or available for its intended mission or for operation. You must do this procedure at the time stated in the interval column. 5. Not Fully Mission Capable If. Information in this column tells you what faults will keep your equipment from being capable of performing its primary mission. If the check and service procedures show faults listed in this column, do not operate the equipment. Follow standard operating procedures for maintaining the equipment or reporting equipment failure

28 TM &P Table 1. Operator Preventive Maintenance Checks and Services Item No. Interval Item to Check/Service Procedure Not Fully Mission Capable If: 1 Daily Couplings, gauges, valves, and vessel seals and joints Visually inspect for signs of fuel leaks 2 Daily Differential pressure gauge Observe differential pressure gauge during operation 3 Daily Sump sight gauge Observe sight gauge during operation 4 Monthly Painted surfaces Check all painted surfaces for rust, chips, peeling, or damage revealing bare metal Any fuel leaks are visible Differential pressure gauge reading is in RED area Sight gauge water level is in the HIGH range Excessive rust, peeling or damaged paint impedes normal operation of unit END OF WORK PACKAGE

29 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM PREPARATION FOR OPERATION In normal operation, the filter/separator is filled with diesel/jet fuel. Diesel/jet fuel may explode if subjected to high temperatures, sources of ignition or high pressure. Keep all open flames, cigarettes, and any other sources of fire/flame or ignition a minimum of 50 yards from any fuel servicing operations. Failure to follow this warning may result in injury or death to personnel. Diesel/jet fuel fumes are toxic in high concentrations. Avoid prolonged breathing of vapors. Operation and maintenance of the filter/separator should be performed only in a well-ventilated environment. Failure to follow this warning may result in injury or death to personnel. 1. Position filter/separator unit on a level surface in a position convenient to fuel supply and fueling hoses. 2. Ensure that ground cable is securely fastened to ground rod. 3. Drive ground rod securely into ground to a minimum depth of 3 feet. 4. Check that ground cable is securely connected to filter/separator frame. END OF WORK PACKAGE /( blank)

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31 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM OPERATION INITIAL SETUP: Tools and Special Tools Protective goggles Nitrile gloves Materials/Parts None Personnel Required One References WP Equipment Condition Pre-operation procedures performed (WP ) INTRODUCTION This work package provides instructions for operating all the filter/separator units. Procedures are the same for all models

32 TM &P OPERATION UNDER USUAL CONDITIONS Figure 1. Filter/Separator Unit Operation In normal operation, the filter/separator is filled with diesel/jet fuel. Diesel/jet fuel may explode if subjected to high temperatures, sources of ignition or high pressure. Keep all open flames, cigarettes, and any other sources of fire/flame or ignition a minimum of 50 yards from any fuel servicing operations. Failure to follow this warning may result in injury or death to personnel. Diesel/jet fuel fumes are toxic in high concentrations. Avoid prolonged breathing of vapors. Operation and maintenance of the filter/separator should be performed only in a well-ventilated environment. Failure to follow this warning may result in injury or death to personnel. Diesel/jet fuel is toxic and can severely affect skin, eyes and the respiratory tract. Personnel must wear appropriate hand and eye protection (nitrile gloves and goggles). Wash skin thoroughly with soap and water if exposed. In case of contact with diesel/jet fuel, flush eyes with clear water for at lest 15 minutes. Failure to follow this warning may result in injury or death to personnel. NOTE The detector kit can be placed in inlet or outlet side of vessel. 1. If fuel sampling will be conducted, install detector kit (figure 1, 3) on filter/separator inlet or outlet connection (5 or 8) and close camlocks completely. 2. With the pump turned off and no fuel flowing, attach supply hose to inlet connection (5) and close camlocks completely. 3. Attach fueling hose to outlet connection (8) and close camlocks completely

33 TM &P Purge valve may release a small amount of fuel during venting. Wear protective gear when venting and place a rag over valve. 4. Open the air purge valve (1) by turning counter-clockwise. 5. Start system pump and set to low speed. Rapid filling of the filter/separator can cause a buildup of static electricity, leading to possible explosion. Fill filter/separator units slowly to minimize static buildup. Failure to follow this warning may result in injury or death to personnel. Recommended flow rates are: 50-GPM 100-GPM 350-GPM 2 GPM 3.5 GPM 11 GPM NOTE 6. Open external upstream valve slightly to fill vessel slowly. 7. As vessel fills, observe purge valve (figure 1, 1) and stop filling vessel when purge valve (1) stops venting air. 8. Close purge valve (1) by turning clockwise. 9. When vessel is full, check all connections for possible leaks. 10. Open downstream valve or nozzle and adjust pump speed to obtain desired flow rate. See WP for maximum flow rate for each model of filter/separator. 11. During operation, periodically observe differential pressure gauge (2). If gauge indication reaches red indicator, coalescers should be replaced. See WP for replacement procedures. 12. During operation, samples of filtered fuel can be taken from sampling port (3) using an appropriate sampling device to determine amount of water in fuel. 13. During operation, periodically observe sight gauge (7). If water level float in sight gauge (7) approaches HIGH mark, stop operation and open purge valve (1) and water drain valve (6) to empty sump. Refer to steps 1 through 9 and repeat process for filling vessel

34 TM &P Rapid closure of downstream valves or nozzles during fueling with a high-pressure pump can result in overpressurization of vessel and cause fuel leaks, leading to possible explosion. Failure to follow this warning may result in injury or death to personnel. NOTE Water should be drained from the sump daily, or after each fueling operation. See Post-Operation Procedures on page for more information. POST-OPERATION PROCEDURES Figure 2. Filter/Separator Unit Post-Operation 1. When fueling operations are complete, shut down pumping system and close upstream and downstream valves to isolate filter/separator. 2. Open purge valve (figure 2, 1) by turning counter-clockwise. 3. Place a suitable container under water drain valve (2) and open water drain valve (2) to drain any water that has accumulated in sump. 4. When all water has drained and green ball in sight gauge (3) reaches bottom, fuel will begin to flow from valve. Close water drain valve (2). 5. Dispose of contaminated liquids in accordance with federal and local regulations

35 TM &P NOTE If filter/separator vessel is to remain installed in fueling system, open upstream valve and refer to Operation Under Usual Conditions on page to fill vessel with fuel. 6. If filter/separator vessel is to be removed and relocated, obtain a suitable container and place it below fuel drain valve (4). Diesel/jet fuel is toxic to skin, eyes and respiratory tract. Personnel must wear appropriate hand and eye protection (nitrile gloves and goggles). Wash skin thoroughly with soap and water if exposed. Flush eyes with clear water for at least 15 minutes in case of contact with diesel/jet fuel. 7. Open fuel drain valve (4) and drain contents of vessel. 8. When all fuel has drained, close fuel drain valve (4) and purge valve (1) and disconnect hoses from inlet and outlet couplings. 9. If installed, disconnect and stow detector kit. 10. Drain residual fuel from hoses. 11. Dispose of excess fuel in accordance with federal and local regulations. END OF WORK PACKAGE /( blank)

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37 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, , AND 350-GPM FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION A PMCS table, Table 1, has been provided so you can keep your equipment in good operating condition and ready for its primary mission. Always observe WARNINGS and CAUTIONS appearing in the PMCS table. WARNINGS and CAUTIONS appear before the procedure to which they apply. WARNINGS and CAUTIONS must be observed to avoid serious injury to yourself and others and to prevent damage to the equipment. The following paragraphs describe the columns of the PMCS table 1. Item No. Numbers in this column are for reference. When completing DA Form 2404 (Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indicating a fault. Item numbers appear in the order of completion for the intervals listed. 2. Interval. This column tells you when the corresponding procedure must be performed. BEFORE procedures must be done before you operate or use the equipment for its intended mission. DURING procedures must be done during the time you are operating or using the equipment for its intended mission. AFTER procedures must be done immediately after you have operated or used the equipment. 3. Item to Check/Service. This column lists the name of the item to be checked or serviced. 4. Procedure. This column gives the procedure to follow to perform the required check or service and determine if the equipment is ready or available for its intended mission or for operation. You must do this procedure at the time stated in the interval column. 5. Not Fully Mission Capable If. Information in this column tells you what faults will keep your equipment from being capable of performing its primary mission. If the check and service procedures show faults listed in this column, do not operate the equipment. Follow standard operating procedures for maintaining the equipment or reporting equipment failure. Table 1. Field Maintenance Preventive Maintenance Checks and Services ITEM NO. INTERVAL ITEM TO CHECK/SERVICE 1 Quarterly Retaining Band Bolts (50- and 100-GPM) PROCEDURE Check for tightness and torque as required NOT FULLY MISSION CAPABLE IF: Loose or damaged 2 Quarterly Lid Bolts (350-GPM) Check for tightness and Loose or damages torque as required 3 Quarterly Differential Pressure Gauge Check for damage Gauge is damaged 4 Quarterly Sight Gauge Check body for cracks and ball float for damage Gauge is damaged 5 Quarterly Ground Rod Check for missing or damaged sections 6 Quarterly Frame and Vessel Inspect for damage. Clean and repaint Ground rod or connections are missing or damaged Tank leaks or frame is damaged such that it does not fully protect vessel and fittings. END OF WORK PACKAGE /( blank)

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39 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM TROUBLESHOOTING INTRODUCTION Table 1 lists common malfunctions that you may find with your equipment. Perform the tests, inspections, and corrective actions in the order they appear in the table. This table cannot list all the malfunctions that can occur, all tests and inspections needed to find the fault, or all the corrective actions needed to correct the fault. If the equipment malfunction is not listed or actions listed do not correct the fault, notify your supervisor. Table 1. Troubleshooting MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION Differential pressure gauge indication is in the RED area of the gauge. Fuel leaking from input or output coupling 1. Check pump operating speed and 1. Adjust pump speed as necessary verify that it is within specified limits 2. Coalescer element contaminated 2. Immediately cease operation and replace all canisters and coalescer elements 1. Verify that camlocks are securely 1. Secure camlocks properly fastened 2. Stop operation and inspect couplings to verify that gaskets are in place, properly seated, and free from damage Fuel leaking from vessel cover 1. Check retaining band (50- and 100- GPM) nuts for proper tightness. 2. Check lid nuts (350-GPM) for proper tightness 2. Properly seat gaskets or replace defective gaskets 1. Ensure retaining band locks properly, with nut torqued to 14 ftlbs. (50- and 100-GPM). 2. Ensure lid bolts are torqued to 150 ft-lbs. (350-GPM). Sudden drop in differential pressure gauge indication Filter/Separator output flow is inadequate 3. Inspect head assembly o-ring for wear or damage 1. Check for ruptured coalescer elements 1. Check pump flow rate and performance 2. Inspect discharge line for kinks or obstructions 3. Check differential pressure gauge and verify that reading is within limits (below red/15) 3. Remove head assembly and replace o-ring 1. Replace all coalescer elements 1. Perform maintenance on pump 2. Remove obstructions and straighten line as necessary 3. If reading is above limit, cease operations and replace all coalescer elements. END OF WORK PACKAGE /( blank)

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41 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, 350-GPM ELEMENT REPLACEMENT INITIAL SETUP: Tools and Special Tools General Mechanics Tool Kit 3/8 Drive Torque Wrench (Item 2, WP ) 1/2 Drive Torque Wrench (Item 3, WP ) Socket, 1 5/16, 1/2-in. drive (Item 7, WP ) Combination wrench, 1 5/16 (Item 9, WP ) Rubber Mallet (Item 4, WP ) Deep Socket, 1/2 (Item 6, WP ) Protective goggles Nitrile gloves Cleaning cloth (Item 3, WP ) Drip Pan (Item 2, WP ) Materials/Parts Coalescer, 50-GPM (Item 5, Figure 1, WP ) Coalescer, 100-GPM (Item 5, Figure 3, WP ) Coalescer, 350-GPM (Item 6, Figure 4, WP ) O-ring (Item 1, WP ) Self-locking nut (Item 2, WP ) Lockwashers (Item 3, WP ) Personnel Required Two References WP WP WP WP Equipment Condition Fuel Drained (WP ) INTRODUCTION This work package provides instructions for the removal and replacement of the coalescer elements in the filter/separator units

42 TM &P AND 100-GPM UNIT ELEMENT REMOVAL Figure and 100-GPM Unit Element Replacement In normal operation, the filter/separator is filled with diesel/jet fuel. Diesel/jet fuel may explode if subjected to high temperatures, sources of ignition or high pressure, resulting in bodily injury or death to personnel. Keep all open flames, cigarettes, and any other sources of fire/flame or ignition a minimum of 50 yards from any fuel servicing operations. Diesel/jet fuel is toxic to skin, eyes and respiratory tract. Personnel must wear appropriate hand and eye protection (nitrile gloves and goggles). Wash skin thoroughly with soap and water if exposed. Flush eyes with clear water for at lest 15 minutes in case of contact with diesel/jet fuel. Diesel/jet fuel fumes are toxic in high concentrations. Avoid prolonged breathing of vapors. Operation and maintenance of the filter/separator should be performed only in a well-ventilated environment. Failure to follow this warning may result in injury or death to personnel. CAUTION Inside surfaces of vessel cover should not be touched in order to minimize the possibility of contamination of the filter/separator unit. Do not place the vessel cover on the bare ground or in grass to avoid possible contamination. 1. Unscrew self-locking nut (figure 1, 4) on retaining band (3) and remove retaining band (3) and head assembly (1). Discard self-locking nut (4). 2. Remove o-ring (2) from vessel (7). 3. Press canister (5) down and turn counter-clockwise approximately 120 degrees to disengage locking mechanism

43 TM &P NOTE Coalescer element may remain in vessel when canister is removed in the following step. 4. Remove canister (5) from vessel (7) by pulling straight up out of the vessel. 5. Remove coalescers (6) from canister (5) by tapping open end of canister (5) on clean, hard surface. 6. Dispose of used coalescers (6) in accordance with local and federal regulations. 50- AND 150-GPM UNIT ELEMENT REPLACEMENT CAUTION Handling canisters and coalescers with bare hands can damage or contaminate the unit and shorten service life. Canisters and coalescers should only be handled with nitrile gloves. 1. Inspect o-rings on top and bottom of coalescer (6) for signs of damage. Inspect canister (5) screen for tears. 2. Lubricate o-rings on top and bottom of each coalescer (6) with diesel/jet fuel and install in canister (5). 3. Install canister (5) and coalescer (6) in vessel (7) and secure in place by pressing straight down and turning approximately 120 degrees clockwise. 4. Lubricate o-ring (2) with diesel/jet fuel and install on vessel (7). 5. Install head assembly (1) on vessel (7) and secure head assembly (1) with locking retaining band (3). NOTE To properly seat the retaining band it is necessary to strike the retaining band with a rubber mallet as it is being torqued. 6. While striking retaining band (3) with rubber mallet at points all around the circumference of the vessel, torque new self-locking nut (4) on retaining band (3) to 14 ft-lbs

44 TM &P GPM UNIT ELEMENT REMOVAL Figure GPM Unit Element Replacement Diesel/jet fuel is toxic to skin, eyes and respiratory tract. Personnel must wear appropriate hand and eye protection (nitrile gloves and goggles). Wash skin thoroughly with soap and water if exposed. Flush eyes with clear water for at lest 15 minutes in case of contact with diesel/jet fuel. Diesel/jet fuel fumes are toxic in high concentrations. Avoid prolonged breathing of vapors. Operation and maintenance of the filter/separator should be performed only in a well-ventilated environment. Failure to follow this warning may result in injury or death to personnel. Removing head assembly requires a two-man lift to avoid injury to personnel. CAUTION Inside surfaces of vessel cover should not be touched in order to minimize the possibility of contamination of the filter/separator unit. Do not place the vessel cover on the bare ground or in grass to avoid possible contamination. 1. Remove 14 lid bolts (10), flat washers (9) and (6), lockwashers (5), and nuts (4) and remove head assembly (1). Discard lockwashers (5). 2. Remove o-ring (8) from vessel (7)

45 TM &P Remove canister (2) by pressing down and turn counter-clockwise approximately 120 degrees to disengage locking mechanism. NOTE Coalescer element may remain in vessel when canister is removed in the following step. 4. Remove canister (2) from vessel (7) by pulling straight up out of the vessel. 5. Remove coalescers (3) from canister (2) by pulling straight up from bayonet nozzle. 6. Dispose of used coalescers (3) in accordance with local and federal regulations. 350-GPM UNIT ELEMENT REPLACEMENT CAUTION Handling canisters and coalescers with bare hands can damage or contaminate the unit and shorten service life. Canisters and coalescers should only be handled with nitrile gloves. 1. Inspect o-rings on top and bottom of coalescer (3) for signs of damage. Inspect canister (2) screen for tears. 2. Lubricate o-rings on top and bottom of each coalescer (3) with diesel/jet fuel and install in canister (2). 3. Install canister (2) and coalescer (3) in vessel (7) and secure in place by pressing straight down and turning approximately 120 degrees clockwise. NOTE The head assembly o-ring is a mandatory replacement part. Always install a new o-ring after removal of the head assembly. 4. Lubricate o-ring (8) with diesel/jet fuel and install on vessel (7). 5. Install head assembly (1) and secure with fourteen lid bolts (10), flat washers (9) and (6), new lockwashers (5), and nuts (4). 6. Torque lid bolts (10) to 150 ft-lbs. in a cross pattern according to Figure

46 TM &P Figure 3. Lid Bolt Torqueing Pattern END OF WORK PACKAGE

47 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM SIGHT GAUGE REPLACEMENT INITIAL SETUP: Tools and Special Tools General Mechanics Tool Kit Protective goggles Nitrile gloves Cleaning cloth (Item 3, WP ) Drip Pan (Item 2, WP ) Materials/Parts Sight gauge, 50-GPM (Item 21, Figure 1, WP0019) Sight gauge, 100-GPM (Item 31, Figure 3, WP0019) Sight gauge, 350-GPM (Item 29, Figure 4, WP0019) Compound, Antiseize (Item 2, WP ) Personnel Required One References WP WP Equipment Condition Fuel Drained (WP ) INTRODUCTION This work package provides instructions for replacing the sight gauge. The procedure is the same for all three models of the filter separator. REMOVAL In normal operation, the filter/separator is filled with diesel/jet fuel. Diesel/jet fuel may explode if subjected to high temperatures, sources of ignition or high pressure, resulting in bodily injury or death to personnel. Keep all open flames, cigarettes, and any other sources of fire/flame or ignition a minimum of 50 yards from any fuel servicing operations. Diesel/jet fuel is toxic to skin, eyes and respiratory tract. Personnel must wear appropriate hand and eye protection (nitrile gloves and goggles). Wash skin thoroughly with soap and water if exposed. Flush eyes with clear water for at lest 15 minutes in case of contact with diesel/jet fuel. Diesel/jet fuel fumes are toxic in high concentrations. Avoid prolonged breathing of vapors. Operation and maintenance of the filter/separator should be performed only in a well-ventilated environment. Failure to follow this warning may result in injury or death to personnel

48 TM &P Figure 1. Sight Gauge Replacement NOTE New sight gauge does not come with the float ball installed. You can retain the old float ball from the defective sight gauge for installation in the new gauge, or you can install a new float ball. 1. Unscrew top and bottom outer bolts (figure 1, 1) to remove sight gauge (2) from bushings (8). 2. Remove bushings (8) from vessel ports (7)

49 TM &P NOTE Perform steps 3 and 4 only if you are retaining the float ball for use in the new gauge. If you are using a new float ball, proceed to replacement procedure. 3. Remove top capscrew (6), setscrew (5), and gasket (4) from top of sight gauge (2). 4. Remove float ball (3) from sight gauge (2). REPLACEMENT 1. Insert float ball (3) in sight gauge (2). NOTE Verify that glass tube inside sight gauge is properly oriented before installing setscrew. Glass tube should be turned so that the red background is to the rear of the gauge. Ensure that HIGH and LOW markers on sight gauge are properly oriented. 2. Install gasket (4), setscrew (5), and top capscrew (6). 3. Apply antiseize compound to threads of top and bottom bushings (8). 4. Install bushings (8) in vessel ports (7). 5. Install sight gauge (2) on bushings (8) by alternately tightening top and bottom outer bolts (1). END OF WORK PACKAGE /( blank)

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51 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM DIFFERENTIAL PRESSURE GAUGE REPLACEMENT INITIAL SETUP: Tools and Special Tools General Mechanics Tool Kit Protective goggles Nitrile gloves Cleaning cloth (Item 3, WP ) Drip Pan (Item 2, WP ) Materials/Parts Sight gauge, 50-GPM (Item 13, Figure 1, WP0019) Sight gauge, 100-GPM (Item 9, Figure 3, WP0019) Sight gauge, 350-GPM (Item 16, Figure 4, WP0019) Compound, Antiseize (Item 2, WP ) Personnel Required One References WP WP Equipment Condition Fuel Drained (WP ) INTRODUCTION This work package provides instructions for replacing the differential pressure gauge. The procedure is the same for all three models of the filter separator. In normal operation, the filter/separator is filled with diesel/jet fuel. Diesel/jet fuel may explode if subjected to high temperatures, sources of ignition or high pressure, resulting in bodily injury or death to personnel. Keep all open flames, cigarettes, and any other sources of fire/flame or ignition a minimum of 50 yards from any fuel servicing operations. Diesel/jet fuel is toxic to skin, eyes and respiratory tract. Personnel must wear appropriate hand and eye protection (nitrile gloves and goggles). Wash skin thoroughly with soap and water if exposed. Flush eyes with clear water for at lest 15 minutes in case of contact with diesel/jet fuel. Diesel/jet fuel fumes are toxic in high concentrations. Avoid prolonged breathing of vapors. Operation and maintenance of the filter/separator should be performed only in a well-ventilated environment. Failure to follow this warning may result in injury or death to personnel

52 TM &P Figure 1. Differential Pressure Gauge Replacement REMOVAL NOTE If gauge remains at 0 during operation, replacement is unnecessary. 1. Unscrew two tube nuts (figure 1, 4) and (13) and disconnect from adapter (3) and elbow (14). 2. Remove two bolts (2) and two nuts (1) to remove differential pressure gauge (15) from brackets (16). 3. Remove adapter (3) and elbow (14) from differential pressure gauge (15). 4. Unscrew two tube nuts (6) and (11) and remove tube elbows (5) and (12) from elbows (8) and (10). 5. Unscrew elbows (8) and (10) from vessel ports (7) and (9). REPLACEMENT 1. Apply antiseize compound to threads of two elbows (8) and (10). 2. Install elbows (8) and (10) on vessel. 3. Install two tube elbows (5) and (12) on elbows (8) and (10) and securing by tightening tube nuts (6) and (11)

53 TM &P Install adapter (3) and elbow (14) on differential pressure gauge (15). 5. Connect adapter (3) and elbow (14) to tube elbows (5) and (12) and tighten tube nuts (4) and (13). 6. Install differential pressure gauge (15) on brackets (16) and secure with two bolts (2) and two nuts (1). END OF WORK PACKAGE / blank

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55 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50- AND 100-GPM FUEL AND WATER DRAIN VALVE REPLACEMENT INITIAL SETUP: Tools and Special Tools Combination wrench, 1 1/4 (Item 8, WP ) Combination wrench, 1 (Item 10, WP ) Protective goggles Nitrile gloves Cleaning cloth (Item 3, WP ) Drip Pan (Item 2, WP ) Materials/Parts Drain valve, 50-GPM (Item 27, Figure 1, WP ) Drain valve, 100-GPM (Item 19, Figure 3, WP ) Drain valve, 350-GPM (Item 27, Figure 4, WP ) Compound, Antiseize (Item 2, WP ) Personnel Required One References WP WP WP Equipment Condition Fuel Drained (WP ) INTRODUCTION This work package provides instructions for replacing the fuel and water drain valves. The procedure is the same for all three models of the filter separator. In normal operation, the filter/separator is filled with diesel/jet fuel. Diesel/jet fuel may explode if subjected to high temperatures, sources of ignition or high pressure, resulting in bodily injury or death to personnel. Keep all open flames, cigarettes, and any other sources of fire/flame or ignition a minimum of 50 yards from any fuel servicing operations. Diesel/jet fuel is toxic to skin, eyes and respiratory tract. Personnel must wear appropriate hand and eye protection (nitrile gloves and goggles). Wash skin thoroughly with soap and water if exposed. Flush eyes with clear water for at lest 15 minutes in case of contact with diesel/jet fuel. Diesel/jet fuel fumes are toxic in high concentrations. Avoid prolonged breathing of vapors. Operation and maintenance of the filter/separator should be performed only in a well-ventilated environment. Failure to follow this warning may result in injury or death to personnel

56 TM &P REMOVAL Unscrew drain valve (figure 1, 2) from vessel nipple (1). REPLACEMENT 1. Apply antiseize compound to threads of vessel nipple (1). 2. Install drain valve (2) on vessel nipple (1). END OF WORK PACKAGE Figure 1. Drain Valve Replacement

57 TM &P OPERATOR AND UNIT MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM PURGE VALVE REPLACEMENT INITIAL SETUP: Tools and Special Tools General Mechanics Tool Kit Protective goggles Nitrile gloves Cleaning cloth (Item 3, WP ) Drip Pan (Item 2, WP ) Materials/Parts Purge valve, 50-GPM (Item 2, Figure 1, WP ) Purge valve, 100-GPM (Item 2, Figure 3, WP ) Purge valve, 350-GPM (Item 2, Figure 4, WP ) Compound, antiseize (Item 2, WP ) Personnel Required One References WP WP Equipment Condition Not applicable INTRODUCTION This work package provides instructions for replacing the fuel and water drain valves. The procedure is the same for all three models of the filter separator. In normal operation, the filter/separator is filled with diesel/jet fuel. Diesel/jet fuel may explode if subjected to high temperatures, sources of ignition or high pressure, resulting in bodily injury or death to personnel. Keep all open flames, cigarettes, and any other sources of fire/flame or ignition a minimum of 50 yards from any fuel servicing operations. Diesel/jet fuel is toxic to skin, eyes and respiratory tract. Personnel must wear appropriate hand and eye protection (nitrile gloves and goggles). Wash skin thoroughly with soap and water if exposed. Flush eyes with clear water for at lest 15 minutes in case of contact with diesel/jet fuel. Diesel/jet fuel fumes are toxic in high concentrations. Avoid prolonged breathing of vapors. Operation and maintenance of the filter/separator should be performed only in a well-ventilated environment. Failure to follow this warning may result in injury or death to personnel

58 TM &P REMOVAL Unscrew purge valve (figure 1, 2) from top of head assembly (1). REPLACEMENT 1. Apply antiseize compound to threads of purge valve (2). 2. Install purge valve (2) in top of head assembly (1). END OF WORK PACKAGE Figure 1. Purge Valve Replacement

59 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM BAYONET REPLACEMENT INITIAL SETUP: Tools and Special Tools General Mechanics Tool Kit Bayonet Socket (Item 1, WP ) Torque Wrench, 1/2 drive (Item 3, WP ) Protective goggles Nitrile gloves Cleaning cloth (Item 3, WP ) Drip Pan (Item 2, WP ) Materials/Parts Bayonet, 50-GPM (Item 6, Figure 1, WP ) Bayonet, 100-GPM (Item 6, Figure 3, WP ) Bayonet, 350-GPM (Item 7, Figure 4, WP ) Compound, Antiseize (Item 2, WP ) Personnel Required One References WP WP WP Equipment Condition Canisters and Coalescer Elements removed (WP ) INTRODUCTION This work package provides instructions for replacing the bayonet. The procedure is the same for all three models of the filter separator

60 TM &P In normal operation, the filter/separator is filled with diesel/jet fuel. Diesel/jet fuel may explode if subjected to high temperatures, sources of ignition or high pressure, resulting in bodily injury or death to personnel. Keep all open flames, cigarettes, and any other sources of fire/flame or ignition a minimum of 50 yards from any fuel servicing operations. Diesel/jet fuel is toxic to skin, eyes and respiratory tract. Personnel must wear appropriate hand and eye protection (nitrile gloves and goggles). Wash skin thoroughly with soap and water if exposed. Flush eyes with clear water for at lest 15 minutes in case of contact with diesel/jet fuel. Diesel/jet fuel fumes are toxic in high concentrations. Avoid prolonged breathing of vapors. Operation and maintenance of the filter/separator should be performed only in a well-ventilated environment. Failure to follow this warning may result in injury or death to personnel. Figure 1. Bayonet Replacement REMOVAL Using 1/2-inch drive socket wrench, long extension, and bayonet socket, unscrew bayonet (1) from fitting (2). REPLACEMENT 1. Apply anti-seize pipe antiseize compound to threads of bayonet (1). 2. Install bayonet (1) on fitting (2) and torque to 50 ft-lbs. END OF WORK PACKAGE

61 TM &P OPERATOR AND FIELD MAINTENANCE FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM CAMLOCK REPLACEMENT INITIAL SETUP: Tools and Special Tools General Mechanics Tool Kit Pipe Wrench (Item 5, WP ) Protective goggles Nitrile gloves Cleaning cloth (Item 3, WP ) Drip Pan (Item 4, WP ) Materials/Parts Camlock, Female 50-GPM (Item 26, Figure 1, WP ) Camlock, Male 50-GPM (Item 10, Figure 1, WP ) Camlock, Female 100-GPM (Item 18, Figure 3, WP ) Camlock, Male 100-GPM (Item 24, Figure 3, WP ) Camlock, Female 50-GPM (Item 25, Figure 4, WP ) Camlock, Male 50-GPM (Item 33, Figure 4, WP ) Compound, antiseize (Item 2, WP ) Personnel Required Two References WP WP WP Equipment Condition Fuel Drained and Filter Separator removed from system (WP ) INTRODUCTION This work package provides instructions for replacing the camlocks. The procedure is the same for all three models of the filter separator. In normal operation, the filter/separator is filled with diesel/jet fuel. Diesel/jet fuel may explode if subjected to high temperatures, sources of ignition or high pressure, resulting in bodily injury or death to personnel. Keep all open flames, cigarettes, and any other sources of fire/flame or ignition a minimum of 50 yards from any fuel servicing operations. Diesel/jet fuel is toxic to skin, eyes and respiratory tract. Personnel must wear appropriate hand and eye protection (nitrile gloves and goggles). Wash skin thoroughly with soap and water if exposed. Flush eyes with clear water for at lest 15 minutes in case of contact with diesel/jet fuel. Diesel/jet fuel fumes are toxic in high concentrations. Avoid prolonged breathing of vapors. Operation and maintenance of the filter/separator should be performed only in a well-ventilated environment. Failure to follow this warning may result in injury or death to personnel

62 TM &P Figure 1. Camlock Replacement REMOVAL Inverting the filter/separator unit requires a two-man lift to avoid injury to personnel. Ensure purge valve is fully closed prior to inverting filter/separator unit to prevent spillage of fuel. 1. Invert filter/separator unit to access camlock fittings. 2. Unscrew camlock fitting (figure 1, 1) or (4) from vessel fitting (2) or (3). REPLACEMENT 1. Inspect camlock gaskets and replace if any signs of damage or wear are noted. 2. Apply antiseize compound to threads of vessel fitting (2) or (3). 3. Install camlock fitting (1) or (4) on vessel fitting (2) or (3). END OF WORK PACKAGE

63 TM &P EQUIPMENT MANUAL FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM REFERENCES SCOPE This work package contains all forms, pamphlets, and technical manuals referenced in this manual. FORMS SF 364 SF 368 Report of Discrepancies Product Quality Deficiency Report PAMPHLETS DA PAM Functional Users Manual for the Army Maintenance Management System (TAMMS) TECHNICAL MANUALS TM Procedures for Destruction of Equipment to Prevent Enemy Use END OF WORK PACKAGE /( blank)

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65 TM &P EQUIPMENT MANUAL FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM MAINTENANCE ALLOCATION CHART INTRODUCTION THE ARMY MAINTENANCE SYSTEM MAC This introduction provides a general explanation of all maintenance and repair functions authorized at the two maintenance levels under the Two-Level Maintenance System concept. This MAC designates overall authority and responsibility for the performance of maintenance functions on the identified end item or component. The application of the maintenance functions to the end item or component shall be consistent with the capacities and capabilities of the designated maintenance levels, which are shown on the MAC in column (4) as: Field includes three subcolumns, Crew maintenance (C), Service maintenance (O), and Field maintenance (F). Sustainment includes two subcolumns, Below Depot (H) and Depot (D) The tools and test equipment requirements (immediately following the MAC) list the tools and test equipment (both special tools and common tool sets) required for each maintenance function as referenced from the MAC. The remarks (immediately following the tools and test equipment requirements) contain supplemental instructions and explanatory notes for a particular maintenance function. Maintenance Functions Maintenance functions are limited to and defined as follows: 1. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical characteristics with established standards through examination (e.g., by sight, sound, or feel). This includes scheduled inspection and gagings and evaluation of cannon tubes. 2. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an item and comparing those characteristics with prescribed standards on a scheduled basis, i.e., load testing of lift devices and hydrostatic testing of pressure hoses. 3. Service. Operations required periodically to keep an item in proper operating condition; e.g., to clean (includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gases. This includes scheduled exercising and purging of recoil mechanisms. The following are examples of service functions: a. Unpack. To remove from packing box for service or when required for the performance of maintenance operations. b. Repack. To return item to packing box after service and other maintenance operations. c. Clean. To rid the item of contamination. d. Touch up. To spot paint scratched or blistered surfaces. e. Mark. To restore obliterated identification

66 TM &P Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the operating characteristics to specified parameters. 5. Align. To adjust specified variable elements of an item to bring about optimum or desired performance. 6. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments of test, measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared. 7. Remove/Install. To remove and install the same item when required to perform service or other maintenance functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or system. 8. Paint (ammunition only). To prepare and spray color coats of paint so that the ammunition can be identified and protected. The color indicating primary use is applied, preferably, to the entire exterior surface as the background color of the item. Other markings are to be repainted as original so as to retain proper ammunition identification. 9. Replace. To remove an unserviceable item and install a serviceable counterpart in its place Replace is authorized by the MAC and assigned maintenance level is shown as the third position code of the Source, Maintenance and Recoverability (SMR) code. 10. Repair. The application of maintenance services, including fault location/troubleshooting, removal/installation, disassembly/assembly procedures and maintenance actions to identify troubles and restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly), end item, or system. NOTE The following definitions are applicable to the repair maintenance function: Services. Inspect, test, service, adjust, align, calibrate, and/or replace. Fault location/troubleshooting. The process of investigating and detecting the case of equipment malfunctioning; the act of isolating a fault within a system or Unit Under Test (UUT). Disassembly/assembly. The step-by-step breakdown (taking apart) of a spare/functional group coded item to the level of its least component, that is assigned an SMR code for the level of maintenance under consideration (i.e., identified as maintenance significant). Actions. Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing 11. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely serviceable/operational condition as required by maintenance standards in appropriate technical publications. Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul des not normally return an item to like new condition. 12. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards. Rebuild is the highest degree of material maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (e.g., hours/miles) considered in classifying Army equipment/components. Explanation of Columns in the MAC Column (1) Group Number. Column (1) lists Functional Group Code (FGC) numbers, the purpose of which is to identify maintenance significant components, assemblies, subassemblies, and modules with the Next Higher Assembly (NHA)

67 TM &P Column (2) Component/Assembly. Column (2) contains the item names of components, assemblies, subassemblies, and modules for which maintenance is authorized. Column (3) Maintenance Function. Column (3) lists the functions to be performed on the item listed in column (2). (For a detailed explanation of these functions refer to Maintenance Functions outlined above). Column (4) Maintenance Level. Column (4) specifies each level of maintenance authorized to perform each function listed in column (3), by indicating work time required (expressed as manhours in whole hours or decimals) in the appropriate subcolumn. This work time figure represents the active time required to perform that maintenance function at the indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance function varies at different maintenance levels, appropriate work time figures are to be shown for each level. The work time figure represents the average time required to restore an item (assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical field operating conditions. This time includes preparation time (including any necessary disassembly/assembly time), troubleshooting/fault location time, and quality assurance time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the MAC. The symbol designations for the various maintenance levels are as follows: Field: C Crew maintenance O Service maintenance F Field maintenance Sustainment: H Below Depot maintenance D Depot maintenance NOTE The L maintenance level is not included in column (4) of the MAC. Functions to this level of maintenance are identified by work time figure in the H column of column (4), and an associated reference code is used in the REMARKS column (6). This code is keyed to the remarks and the SRA complete repair application is explained there. Column (5) Tools and Equipment Reference Code. Column (5) specifies, by code, those common tool sets (not individual tools), common Test, Measurement and Diagnostic Equipment (TMDE), and special tools, special TMDE and special support equipment required to perform the designated function. Codes are keyed to the entries in the tools and test equipment table. Column (6) Remarks Code. When applicable, this column contains a letter code, in alphabetical order, which is keyed to the remarks table entries. Explanation of Columns in the Tools and Test Equipment Requirements Column (1) Tool or Test Equipment Reference Code. The tool or test equipment reference code correlates with a code used in column (5) of the MAC. Column (2) Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment. Column (3) Nomenclature. Name or identification of the tool or test equipment. Column (4) National Stock Number (NSN). The NSN of the tool or test equipment

68 TM &P Column (5) Tool Number. The manufacturer's part number, model number, or type number. Explanation of Columns in the Remarks Column (1) Remarks Code. The code recorded in column (6) of the MAC. Column (2) Remarks. This column lists information pertinent to the maintenance function being performed as indicated in the MAC. END OF WORK PACKAGE

69 TM &P EQUIPMENT MANUAL FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM MAINTENANCE ALLOCATION CHART Table 1. MAC for Filter/Separator Units GROUP NUMBER COMPONENT/ASSEMBLY MAINTENANCE FUNCTION MAINTENANCE LEVEL FIELD CREW SERVICE FIELD BELOW DEPOT SUSTAINMENT DEPOT C O F H D TOOLS AND EQUIPMENT REF CODE REMARKS CODE GPM FILTER/SEP 0101 FRAME AND VESSEL Inspect 0.1 Repair 1.0 Replace AIR PURGE VALVE Inspect 0.1 Replace HEAD ASSEMBLY Inspect 0.1 Replace 0.2 B, D 0104 CANISTERS Inspect 0.1 Replace COALESCERS Inspect 0.2 Replace FUEL/WATER DRAIN VALVE Inspect 0.1 Replace 0.2 I Test SIGHT GAUGE Inspect 0.1 Replace DIFFERENTIAL PRESSURE GAUGE Inspect 0.1 Replace CAMLOCK FITTING Inspect 0.1 Replace 0.5 C

70 TM &P Table 1. MAC for Filter/Separator Units, Continued GROUP NUMBER COMPONENT/ASSEMBLY MAINTENANCE FUNCTION MAINTENANCE LEVEL FIELD SUSTAINMENT CREW SERVICE FIELD BELOW DEPOT DEPOT C O F H D TOOLS AND EQUIPMENT REF CODE REMARKS CODE 0010 DETECTOR KIT Inspect 0.1 Replace GPM FILTER/SEP 0201 FRAME AND VESSEL Inspect 0.1 Repair 1.0 Replace AIR PURGE VALVE Inspect 0.1 Replace HEAD ASSEMBLY Inspect 0.1 Replace 0.2 B, D 0204 CANISTERS Inspect 0.1 Replace COALESCERS Inspect 0.2 Replace FUEL/WATER DRAIN VALVE Inspect 0.1 Replace 0.2 F Test SIGHT GAUGE Inspect 0.1 Replace DIFFERENTIAL PRESSURE GAUGE Inspect 0.1 Replace CAMLOCK FITTING Inspect 0.1 Replace 0.5 C 0210 DETECTOR KIT Inspect 0.1 Replace

71 TM &P Table 1. MAC for Filter/Separator Units, Continued GROUP NUMBER COMPONENT/ASSEMBLY MAINTENANCE FUNCTION MAINTENANCE LEVEL FIELD SUSTAINMENT CREW SERVICE FIELD BELOW DEPOT DEPOT C O F H D TOOLS AND EQUIPMENT REF CODE REMARKS CODE GPM FILTER/SEP Inspect 0301 FRAME AND VESSEL Inspect 0.1 Repair 1.0 Replace AIR PURGE VALVE Inspect 0.1 Replace HEAD ASSEMBLY Inspect 0.1 Replace 0.2 E, G, H 0304 CANISTERS Inspect 0.1 Replace 0.1 A 0305 COALESCERS Inspect 0.2 Replace FUEL/WATER DRAIN VALVE Inspect 0.1 Replace 0.2 F Test SIGHT GAUGE Inspect 0.1 Replace DIFFERENTIAL PRESSURE GAUGE Inspect 0.1 Replace CAMLOCK FITTING Inspect 0.1 Replace 0.5 C 0310 DETECTOR KIT Inspect 0.1 Replace

72 TM &P TOOL OR TEST EQUIPMENT REF CODE MAINTENANCE LEVEL END OF WORK PACKAGE Table 2. Tools and Test Equipment for Filter/Separator Units NATIONAL STOCK NUMBER NOMENCLATURE TOOL NUMBER A O Socket, bayonet 493X500_SOCKET B F Torque wrench, 3/8 drive C F Pipe wrench D F Socket, deep, 1/ E F Torque wrench, 1/2 drive F F Wrench, 1-1/ A-A-1358 G F Wrench, 1-5/ A-A-1356 H F Socket, 1-5/ I F Wrench,

73 TM &P EQUIPMENT MANUAL FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM REPAIR PARTS AND SPECIAL TOOLS LIST

74 TM &P Figure 1. Filter/Separator, 50-GPM

75 TM &P (1) (2) (3) (4) (5) (6) (7) ITEM NO. SMR CODE NSN CAGEC PART NUMBER DESCRIPTION AND USABLE ON CODE (UOC) AVV1320MIL FIG. 1 FILTER/SEPARATOR, LIQUID FUELS, P/N AVV1320MIL (50-GPM) 1 PFOZZA Y500 HEAD, FLUID FILTER PBOZZA M-PG4A-SS VALVE, PURGE PBOZZA M45913/3-5FS6 NUT, SELF LOCKING PAOZZA I-420MMA FILTER ELEMENT, FLUID PAOZZA SI-522E FILTER ELEMENT PFOZZA X500 BAYONET PBOZZA AA B ROD, GROUND PBOZZA M45913/1-5CS6 NUT, SELF-LOCKING PBOZZA B1821BH025C088N CAPSCREW PBOZZA AA59326I15 COUPLING HALF PBOZZA AA59326/10-5 CAP, QUICK DISCONN PFOZZA GAUGE, PRESSURE PBOZZA MS NUT, HEX, JAM PAOZZA MS SCREW PFOZZA SA ADAPTER, PIPE TO TUBE PFOZZA Z501 TUBE ASSEMBLY PFOZZA FBUSS ELBOW, PIPE TO TUBE PFOZZA FBUSS ELBOW, PIPE TO TUBE PFOZZA Z500 TUBE ASSEMBLY PFOZZA FBUSS ELBOW, PIPE TO TUBE PBOZZA AA59326X15 PLUG, QUICK DISCONN PBOZZA AA59326G-5 GASKET PBOZZA AA59326V15 COUPLING HALF PBOZZA T13 VALVE, BALL PBOZZA C K14 NIPPLE KFOOOA Y500 DETECTOR KIT PBOZZA X800 BALL, NONMETALLIC PFOZZA G A-1-4-AL INDICATOR, SIGHT PFOZZA X501 PLATE, INSTRUCTION PBOZZA T13 VALVE, BALL PFOZZA X500 PLATE, IDENTIFICATION PFOZZA z500 FRAME ASSEMBLY, SHELL PBOZZA V N-1412 BAND, RETAINING PAOZZA x500 O-RING END OF FIGURE QTY

76 TM &P Figure 2. Detector Kit (1) (2) (3) (4) (5) (6) (7) ITEM NO. SMR CODE NSN CAGEC PART NUMBER DESCRIPTION AND USABLE ON CODE (UOC) QTY FIG. 2 DETECTOR KIT P/N 166Y500 (See Figure 1 for NHA) 1 PFOZZA Y500 NIPPLE, COUPLING PBOZZA AA59326G-5 GASKET END OF FIGURE /( blank)

77

78 TM &P Figure 3. Filter/Separator, 100-GPM

79 TM &P (1) (2) (3) (4) (5) (6) (7) ITEM NO. SMR CODE NSN CAGEC PART NUMBER DESCRIPTION AND USABLE ON CODE (UOC) QTY AVV1620MIL FIG. 3 FILTER/SEPARATOR, LIQUID FUELS, P/N AVV1620MIL (100-GPM) 1 PFOZZA Y600 HEAD, FLUID FILTER PBOZZA M-PG4A-SS VALVE, PURGE PBOZZA M45913/3-5FS6 NUT, SELF LOCKING PAOZZA I-420MMA FILTER ELEMENT, FLUID PAOZZA SI-522E FILTER ELEMENT PFOZZA X500 BAYONET PFOZZA X600 PLATE, IDENTIFICATION PFOZZA X601 PLATE, INSTRUCTION PFOZZA GAUGE, PRESSURE PBOZZA MS NUT, HEX JAM PAOZZA MS SCREW PFOZZA SA ADAPTER, PIPE TO TUBE PFOZZA Z601 TUBE ASSEMBLY PFOZZA FBUSS ELBOW, PIPE TO TUBE PFOZZA Z600 TUBE ASSEMBLY PBOZZA AA59326X16 PLUG, QUICK DISCONN PBOZZA AA59326G-6 GASKET PBOZZA AA59326V16 COUPLING HALF PBOZZA T14 VALVE, BALL PBOZZA X800 BALL, FLOAT PFOZZA G A-1-4-AL INDICATOR, SIGHT KFOOOA Y600 DETECTOR KIT PBOZZA MS COUPLING HALF PFOZZA C K15 NIPPLE, PIPE PBOZZA AA59326G-6 GASKET PBOZZA AA59326IX16 CAP, QUICK DISCONN PBOZZA T14 VALVE, BALL PFOZZA Z600 FRAME ASSEMBLY, SHELL PFOZZA Y600 STANDPIPE PBOZZA A125 NUT, SELF-LOCKING PBOZZA B1821BH025C088N CAPSCREW PBOZZA AA B ROD, GROUND PBOZZA V N-1745 BAND, RETAINING PAOZZA X600 O-RING END OF FIGURE

80 TM &P Figure 4. Filter/Separator, 350-GPM

81 TM &P (1) ITEM NO. (2) SMR CODE (3) NSN (4) CAGEC (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) (7) QTY AVV2820MIL FIG. 3 FILTER/SEPARATOR, LIQUID FUELS, P/N AVV2820MIL (350-GPM) 1 PFOZZA Y700 HEAD, FLUID FILTER PBOZZA M-PG4A-SS VALVE, PURGE PAOZZA MS BOLT PAOZZA MS FLAT WASHER PAOZZA I-420MMA FILTER ELEMENT, FLUID PAOZZA SI-522E FILTER ELEMENT PFOZZA X500 BAYONET PBOZZA B1821BH025C088N CAPSCREW PBOZZA A125 NUT, SELF-LOCKING PBOZZA AA B ROD, GROUND PAOZZA MS FLAT WASHER PAOZZA MS LOCKWASHER PAOZZA MS HEX NUT PFOZZA X700 PLATE, IDENTIFICATION PFOZZA X701 PLATE, INSTRUCTION PFOZZA GAUGE, PRESSURE PBOZZA MS NUT, HEX JAM PAOZZA MS SCREW PFOZZA SA ADAPTER, PIPE TO TUBE PFOZZA Z701 TUBE ASSEMBLY PFOZZA FBUSS ELBOW, PIPE TO TUBE PFOZZA Z700 TUBE ASSEMBLY PBOZZA AA59326X19 PLUG, QUICK DISCONN PBOZZA AA GASKET PBOZZA AA59326/5-9-A-1 COUPLING HALF PBOZZA T14 VALVE, BALL PFOZZA C K K15 NIPPLE, PIPE PBOZZA X800 BALL, FLOAT PFOZZA G A-1-4-AL INDICATOR, SIGHT KFOOOA Y700 DETECTOR KIT PFOZZA C K K15 NIPPLE, PIPE PBOZZA T14 VALVE, BALL PBOZZA AA59326I19 COUPLING HALF PBOZZA AA GASKET PBOZZA AA59326/10-9 CAP, QUICK DISCONN PFOZZA Z700 FRAME ASSEMBLY, SHELL PFOZZA Y700 STANDPIPE PAOZZA X700 O-RING END OF FIGURE

82 TM &P (1) ITEM NO. (2) SMR CODE (4) CAGEC END OF WORK PACKAGE Figure 5. Special Tools (5) PART NUMBER (6) DESCRIPTION AND USABLE ON CODE (UOC) FIG. 4 SPECIAL TOOLS X500_SOCKET SOCKET, Bayonet TORQUE WRENCH, 3/8 DRIVE TORQUE WRENCH, 1/2 DRIVE RUBBER MALLET PIPE WRENCH SOCKET, DEEP, 7/16 1/2-INCH DRIVE SOCKET, 1 5/16, 1/2-INCH DRIVE WRENCH, COMBINATION, 1 1/ WRENCH, COMBINATION, 1 5/ WRENCH, COMBINATION, 1 1 END OF FIGURE (7) QTY

83 TM &P EQUIPMENT MANUAL FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, 350-GPM COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS INTRODUCTION Scope This work package lists COEI and BII for the filter/separator to help you inventory items for safe and efficient operation of the equipment. General The COEI and BII information is divided into the following lists: Components of End Item (COEI). This list is for information purposes only and is not authority to requisition replacements. These items are part of the filter/separator. As part of the end item, these items must be with the end item whenever it is issued or transferred between property accounts. Items of COEI are removed and separately packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify the items. Basic Issue Items (BII). These essential items are required to place the filter/separator in operation, operate it, and to do emergency repairs. Although shipped separately packaged, BII must be with the filter/separator during operation and when it is transferred between property accounts. Listing these items is your authority to request/requisition them for replacement based on authorization of the end item by the TOE/MTOE., Illustrations are furnished to help you find and identify the items. Explanation of Columns in the COEI List and BII List Column (1) Illus Number. Gives you the number of the item illustrated. Column (2) National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning purposes. Column (3) Description, CAGEC, and Part Number. Identifies the Federal item name (in all capital letters) followed by a minimum description when needed. The stowage location of COEI and BII is also included in this column. The last line below the description is the CAGEC (Commercial and Government Entity Code) (in parentheses) and the part number. Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different models of equipment. These codes are identified below: Code Used on A 50-GPM Unit (NSN ) B 100-GPM Unit (NSN ) C 350-GPM Unit (NSN ) Column (5) Unit of Issue (U/I). Indicates the physical measurement or count of the item as issued per the National Stock Number shown in column (2). Column (6) Qty Rqr. Indicates the quantity required

84 TM &P Figure 1. Components of End Item Table 1. Components of End Item List (1) ILLUS NUMBER (2) NATIONAL STOCK NUMBER (3) DESCRIPTION, CAGEC, AND PART NUMBER FILTER SEPARATOR, LIQUID FUELS, 50 GPM, (13573) AVV1320MIL FILTER SEPARATOR, LIQUID FUELS, 100 GPM, (13573) AVV1620MIL FILTER SEPARATOR, LIQUID FUELS, 350 GPM, (13573) AVV2820MIL (6) QTY RQR

85 TM &P Figure 2. Basic Issue Items Table 2. Basic Issue Items List (1) ILLUS NUMBER (2) NATIONAL STOCK NUMBER (3) DESCRIPTION, CAGEC, AND PART NUMBER 1 DETECTOR KIT, (13573) 166Y500 DETECTOR KIT, (13573) 166Y600 DETECTOR KIT, (13573) 166Y700 2 TECHNICAL MANUAL (13573) TM &P (4) USABLE ON CODE (5) U/I (6) QTY RQR A EA 1 B EA 1 C EA 1 A, B, C EA 1 END OF WORK PACKAGE /( blank)

86

87 TM &P EQUIPMENT MANUAL FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, 350-GPM ADDITIONAL AUTHORIZATION LIST There are no additional authorized items for the filter/separators. END OF WORK PACKAGE /( blank)

88

89 TM &P EQUIPMENT MANUAL FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM EXPENDABLE AND DURABLE ITEMS LIST INTRODUCTION Scope This work package lists expendable and durable items that you will need to operate and maintain the (enter equipment/end item name). This list is for information only and is not authority to requisition the listed items. These items are authorized to you by CTA , Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items), or CTA 8-100, Army Medical Department Expendable/Durable Items. Explanation of Columns in the Expendable/Durable Items List Column (1) Item Number. This number is assigned to the entry in the list and is referenced in the narrative instructions to identify the item (e.g., Use brake fluid (item 5, WP ). ). Column (2) Level. This column identifies the lowest level of maintenance that requires the listed item (include as applicable: C = Operator/Crew, O = Unit/AVUM, F = Direct Support/AVIM, H = General Support, D = Depot). Column (3) National Stock Number (NSN). This is the NSN assigned to the item which you can use to requisition it. Column (4) Item Name, Description, Commercial and Government Entity Code (CAGEC), and Part Number (P/N). This column provides the other information you need to identify the item. Column (5) Unit of Issue (U/I). Indicates the physical measurement or count of the item as issued per the National Stock Number shown in column (3). (1) ITEM NUMBER Table 1. Expendable and Durable Items List (2) LEVEL (3) NATIONAL STOCK NUMBER (4) ITEM NAME, DESCRIPTION, CAGEC, AND PART NUMBER 1 C DETERGENT, GENERAL PURPOSE BX 2 O COMPOUND, ANTISEIZE (TT-S-1732), 5W425, CN P/N NPBT-8 3 O CLOTH, CLEANING, BX 4 O DRIP PAN, METAL, RECTANGULAR, EA (5) U/I END OF WORK PACKAGE /( blank)

90

91 TM &P EQUIPMENT MANUAL FILTER/SEPARATOR, LIQUID FUEL, 50-, 100-, AND 350-GPM MANDATORY REPLACEMENT PARTS INTRODUCTION This work package includes a list of all mandatory replacement parts referenced in the task initial setups and procedures. These are items that must be replaced during maintenance whether they have failed or not. This includes items based on usage intervals such as miles, time, rounds, fired, etc. ITEM NUMBER PART NUMBER/CAGEC END OF WORK PACKAGE Table 1. Mandatory Replacement Parts List NATIONAL STOCK NUMBER NOMENCLATURE 1 421X700, O-RING 1 2 M45913/3-5FS6, NUT, SELF-LOCKING 1 3 MS , LOCKWASHER 28 QTY /( blank)

92

93 TM &P INDEX A A-A WP AAL...WP Additional Authorization List...WP AR WP B Basic Issue Items...WP Bayonet Description...WP , WP Replacement...WP Bayonet Mount Description...WP BII...WP C Camlock Replacement...WP Canister Description...WP Canister Description...WP , WP Capabilities...WP Coalescer Description...WP , WP , WP Replacement...WP COEI...WP Components of End Item...WP Controls and Indicators...WP Differential Pressure Gauge...WP Fuel Drain Valve...WP Purge Valve...WP Sight Gauge...WP Water Drain Valve...WP Corrosion Prevention and Control...WP D DA PAM WP DA PAM WP Daily Maintenance...WP DAPAM WP INDEX-1

94 TM &P Destruction of Army Materiel To Prevent Enemy Use...WP Detector Kit Description...WP , WP , WP Detector Kit, Use of...wp Differential Pressure Gauge Description...WP , WP , WP Functional Description...WP Inspection...WP Replacement...WP Dimensions 100-GPM unit...wp GPM unit...wp GPM unit...wp Drain Valve, Fuel Description...WP , WP , WP Drain Valve, Water Description...WP , WP , WP E EIR...WP Element Replacement...WP Equipment Characteristics...WP Equipment Improvement Recommendation...WP Equipment Name...WP Equipment Purpose...WP Expendable and Durable Items List...WP F Frame and Vessel Description...WP , WP Inspection...WP Fuel Drain Valve Description...WP , WP Functional Description...WP Replacement...WP Fuel Drain Valve Description...WP Fuels Processed...WP G Ground Rod Description...WP , WP Inspection...WP Setup...WP Grounding Rod Description...WP INDEX-2

95 TM &P H Head Assembly Description...WP Head Assembly Description...WP , WP I Inlet Coupling Description...WP Inlet Coupling Description...WP , WP Inspection...WP , WP M MAC...WP Maintenance Bayonet Replacement...WP Camlock Replacement...WP Daily...WP Differential Pressure Gauge Replacement...WP Element Replacement...WP Fuel Drain Valve Replacement...WP Monthly...WP Purge Valve Replacement...WP Quarterly...WP Sight Gauge Replacement...WP Water Drain Valve Replacement...WP Maintenance Allocation Chart...WP Maintenance Forms and Records...WP Mandatory Replacement Parts...WP Maximum Flow Rate 100-GPM unit...wp GPM unit...wp GPM unit...wp Maximum Working Pressure 100-GPM unit...wp GPM unit...wp GPM unit...wp MIL-DTL WP MIL-DTL WP Monthly Maintenance...WP O Operating Temperature Range 100-GPM unit...wp GPM unit...wp GPM unit...wp INDEX-3

96 TM &P Operation...WP O-ring Description...WP , WP Outlet Coupling Description...WP , WP , WP P PMCS Field...WP Operator...WP Preparation for Operation...WP Preventive Maintenance Checks and Services Field...WP Operator...WP Principles of Operation...WP Purge Valve Description...WP , WP , WP Functional Description...WP Replacement...WP Q Quarterly Maintenance...WP R References...WP Repair Parts...WP Reporting Equipment Improvement Recommendation...WP S Scope...WP SF WP Sight Gauge Description...WP , WP , WP Functional Description...WP Inspection...WP Replacement...WP Special Tools...WP , WP Storage Temperature Range 100-GPM unit...wp GPM unit...wp GPM unit...wp INDEX-4

97 TM &P T TM WP Tools, Special...WP , WP Troubleshooting...WP V V-Band Description...WP , WP Inspection...WP W Water Drain Valve Description...WP Functional Description...WP Replacement...WP Water Drain Valve Description...WP , WP Weight 100-GPM unit...wp GPM unit...wp GPM unit...wp INDEX-5/(INDEX-6 blank)

98

99

100

101 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA Use Part II(reverse)for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). DATE TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code) PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE ITEM PAGE PARA- LINE FIGURE NO. TABLE RECOMMENDED CHANGES AND REASON TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. APD V4.00

102 TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE PART II - REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFEREN FIGURE CENO. NO. ITEM NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION PART III - REMARKS (Any genera/ remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.) TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE APD V4.00

103 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 310-1; the proponent agency is the US Army Adjutant General Center. Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). DATE TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code) PART I - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE ITEM NO. PAGE NO. PARA- GRAPH LINE NO.* FIGURE NO. TABLE NO. RECOMMENDED CHANGES AND REASON (Exact wording of recommended change must be given) TYPED NAME, GRADE OR TITLE * Reference to line numbers within the paragraph or subparagraph. TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION DA FORM 1 FEB REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

104 TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code) DATE PART II- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION/FORM NUMBER DATE TITLE PAGE NO. COLM NO. LINE NO. FEDERAL STOCK NUMBER REFERENCE NO. FIGURE NO. ITEM NO. TOTAL NO. OF MAJOR ITEMS SUPPROTED RECOMMENDED ACTION PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.) TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE U.S. GOVERNMENT PRINTING OFFICE /8606

105 TM By Order of the Secretary of the Army: GEORGE W. CASEY, JR. General, United States Army Chief of Staff Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army Distribution: To be distributed in accordance with the Initial Distribution Number (IDN) requirements for TM

106

107 LINEAR MEASURE 1 Centimeter = 10 Millimeters = 0.01 Meters = Inches 1 Meter = 100 Centimeters = 1,000 Millimeters = Inches 1 Kilometer = 1,000 Meters = Miles SQUARE MEASURE 1 Sq Centimeter = 100 Sq Millimeters = Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = Sq Miles CUBIC MEASURE 1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = Cu Feet THE METRIC SYSTEM AND EQUIVALENTS LIQUID MEASURE 1 Milliliter = Liters = Fluid Ounces 1 Liter = 1,000 Milliliters = Fluid Ounces TEMPERATURE Degrees Fahrenheit (F) = C Degrees Celsius (C) = F Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32.2 Celsius 32 Fahrenheit is equivalent to 0 Celsius WEIGHTS 1 Gram = Kilograms = 1,000 Milligrams = Ounces 1 Kilogram = 1,000 Grams = 2.2 Lb 1 Metric Ton = 1,000 Kilograms = 1 Megagram = 1.1 Short Tons APPROXIMATE CONVERSION FACTORS TO CHANGE TO MULTIPLY BY Inches Millimeters Inches Centimeters Feet Meters Yards Meters Miles Kilometers Square Inches Square Centimeters Square Feet Square Meters Square Yards Square Meters Square Miles Square Kilometers Acres Square Hectometers Cubic Feet Cubic Meters Cubic Yards Cubic Meters Fluid Ounces Milliliters Pints Liters Quarts Liters Gallons Liters Ounces Grams Pounds Kilograms Short Tons Metric Tons Pound-Feet Newton-Meters Pounds Per Square Inch Kilopascals Miles Per Gallon Kilometers Per Liter Miles Per Hour Kilometers Per Hour TO CHANGE TO MULTIPLY BY Millimeters Inches Centimeters Inches Meters Feet Meters Yards Kilometers Miles Square Centimeters Square Inches Square Meters Square Feet Square Meters Square Yards Square Kilometers Square Miles Square Hectometers Acres Cubic Meters Cubic Feet Cubic Meters Cubic Yards Milliliters Fluid Ounces Liters Pints Liters Quarts Liters Gallons Grams Ounces Kilograms Pounds Metric Tons Short Tons Newton-Meters Pound-Feet Kilopascals Pounds Per Square Inch Kilometers Per Liter Miles Per Gallon Kilometers Per Hour Miles Per Hour INCHES CENTIMETERS

108 PIN:

109 This fine document... Was brought to you by me: Liberated Manuals -- free army and government manuals Why do I do it? I am tired of sleazy CD-ROM sellers, who take publicly available information, slap watermarks and other junk on it, and sell it. Those masters of search engine manipulation make sure that their sites that sell free information, come up first in search engines. They did not create it... They did not even scan it... Why should they get your money? Why are not letting you give those free manuals to your friends? I am setting this document FREE. This document was made by the US Government and is NOT protected by Copyright. Feel free to share, republish, sell and so on. I am not asking you for donations, fees or handouts. If you can, please provide a link to liberatedmanuals.com, so that free manuals come up first in search engines: <A HREF= Military and Government Manuals</A> Sincerely Igor Chudov Chicago Machinery Movers